EP0897020B1 - Endabmessungsnahe Mehrschichtkomponenten einer Verbrennungsvorrichtung, gemäss des Vakuum-Plasmaspritzverfahrens und Verfahren zu dessen Herstellung - Google Patents

Endabmessungsnahe Mehrschichtkomponenten einer Verbrennungsvorrichtung, gemäss des Vakuum-Plasmaspritzverfahrens und Verfahren zu dessen Herstellung Download PDF

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Publication number
EP0897020B1
EP0897020B1 EP98112560A EP98112560A EP0897020B1 EP 0897020 B1 EP0897020 B1 EP 0897020B1 EP 98112560 A EP98112560 A EP 98112560A EP 98112560 A EP98112560 A EP 98112560A EP 0897020 B1 EP0897020 B1 EP 0897020B1
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Prior art keywords
mold
component
layer
top coat
vacuum plasma
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EP98112560A
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English (en)
French (fr)
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EP0897020A1 (de
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Peter G. Tsantrizos
George E. Kim
Alexander Cavasin
Serge Grenier
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Pyrogenesis Inc
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Pyrogenesis Inc
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment
    • C23C4/185—Separation of the coating from the substrate
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/922—Static electricity metal bleed-off metallic stock
    • Y10S428/9335—Product by special process
    • Y10S428/937—Sprayed metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12472—Microscopic interfacial wave or roughness
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
    • Y10T428/12611—Oxide-containing component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
    • Y10T428/12611—Oxide-containing component
    • Y10T428/12618—Plural oxides
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12736—Al-base component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771—Transition metal-base component
    • Y10T428/12861—Group VIII or IB metal-base component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771—Transition metal-base component
    • Y10T428/12861—Group VIII or IB metal-base component
    • Y10T428/12931—Co-, Fe-, or Ni-base components, alternative to each other

Definitions

  • This invention relates to improved multilayered combustion system components, such as combustor liners or transition ducts of a gas turbine engine, wherein the inner surface comprises a protective thermal barrier coating (TBC), which includes a ceramic top coat and a metallic bond coat, and the outer surface consists of a structural layer bonded to the TBC through the bond coat.
  • TBC protective thermal barrier coating
  • the improved qualities of the new components over current components include a superior thermal barrier coating, a better high-temperature structural material, a smoother inside surface, no irregularities (welds) within the component, and excellent reproducibility.
  • This is accomplished by a vacuum plasma spray (VPS) process which is used to form the ceramic top coat layer on a suitable mold, followed by a metallic bond coat layer and ending with a structural superalloy layer. Thereafter, the mold is removed to form the multilayered component of the present invention.
  • VPS vacuum plasma spray
  • TBC's consisting of a ceramic top coat and a metallic bond coat (typically an MCrAlY) on the inner surface of preformed combustion system components.
  • a metallic bond coat typically an MCrAlY
  • Two of the components protected by such coatings are combustor liners and transition ducts, which contain the combustion flame and channel the extremely hot gas (> 1,300°C) to the first stage vanes.
  • the transition ducts in particular have a fairly complex geometry and the presently known technology does not allow for satisfactory coating of internal surfaces of components with such complex geometries.
  • combustion system components such as combustor liners and transition ducts
  • the current fabrication process of combustion system components consists of: (i) mechanically forming two or more individual sections of the component; (ii) plasma spraying by atmospheric plasma spray (APS) the inner surface of each section to form the thermal barrier coating system; (iii) welding the sections so coated; (iv) plasma spraying by APS the protective TBC coatings on the welds whenever possible; and, for transition ducts, (v) laser drilling cooling holes through the structural wall and the coating.
  • APS atmospheric plasma spray
  • APS plasma spraying by APS the protective TBC coatings on the welds whenever possible
  • laser drilling cooling holes through the structural wall and the coating.
  • Weld regions act as weak sites from which failure may initiate due to poor quality finish of both the top coat and the bond coat of the TBC. Also, due to the rough surface of the TBC inherent in the APS process and particularly of the weld regions, an undesirable change in flow pattern of the hot gas is often produced. Moreover, because the current fabricating process consists of mechanically forming sections of the component followed by welding and spraying inner surfaces of these sections, there is a limitation on the choice of suitable superalloys. Only superalloys with high elongation such as, nickel-chromium alloys known under trade names Haynes 230, IN-617, etc. are suitable. Superalloys which do not possess the required elongation or ductility cannot be used with the current fabrication process, even if they possess other superior properties, such as better high temperature strength and creep resistance, e.g. IN-738LC superalloy.
  • HPTEI High Performance Turbine Engine Initiative
  • ATS Advanced Turbine System
  • Gas turbine hot-section materials constitute an important limiting factor and are critical to achieving the higher firing temperatures.
  • Current methods of producing closed combustion system components, e.g., combustor liners and transition ducts, to contain and guide the hot gas, have inherent limitations which are difficult to overcome, especially in more demanding conditions, such as higher temperatures and pressures.
  • Another object is to provide combustion system components which resist high gas temperatures of the order of 800°C - 1600°C.
  • a still further object of the present invention is to form components with a protective inner TBC, which do not require welding as an integral part of the fabrication process.
  • novel components of the present invention are near net-shape VPS formed multilayered combustion system components, such as combustor liners or transition ducts, which comprise:
  • the ceramic top coat is normally of a thickness greater than 250 ⁇ m and preferably greater than 1 mm.
  • the preferred range of the top coat thicknesses is between 1 and 1.5 mm.
  • It is formed of ceramic materials such as zirconia (ZrO 2 ) and calcia-silica (Ca 2 SiO 4 ).
  • ZrO 2 may be partially stabilized with yttria (Y 2 O 3 ) as is known in the art.
  • the metallic bond coat is made of MCrAlY where M is Ni, Co, Fe or a combination thereof.
  • M is Ni, Co, Fe or a combination thereof.
  • CoNiCrAlY is an excellent bond coat material when sprayed to a thickness of between about 100 - 200 ⁇ m.
  • Such material is already described, for example, in U.S. patent No. 5,384,200 of January 24, 1995, where it is deposited as part of a TBC on the surface of combustion chamber components by plasma spray; the components themselves in that case are, however, not formed by plasma spray and furthermore no use of VPS is disclosed.
  • the near net-shape VPS formed outer structural superalloy layer is normally formed of a nickel-base or cobalt-base superalloy having good structural and thermal resistance properties, such as Inconel, Hastelloy or Haynes Alloy, however, unlike known technology where such alloys had to be mechanically preformed and, therefore, had to possess sufficient elongation and ductility for that purpose; in the present case, any desired superalloy may be employed, since the outer structure is also formed in accordance with the present invention by vacuum plasma spray unlike anything taught by the prior art for such multilayered applications.
  • a superalloy such as IN-738LC which has excellent high temperature resistance properties, but is too brittle to be mechanically formed, can now be used within the present invention.
  • the structural superalloy layer is usually between 1 and 5 mm thick, and should be capable of withstanding temperatures in excess of 700 °C. Because it is formed by VPS, it has no seams or welds and it may be deposited to different predetermined thicknesses within the same component, which is very useful for components with complex geometries, such as the transition duct, where it may be desirable to have a thicker structure wall in some areas of the component. Such thicker build-ups may be spray formed, according to this invention, within the same overall operation, i.e. when the entire multilayered structure of the component is being formed.
  • Both the bond coat and the structural layer are normally built-up with dense microstructures, typically less than 1.5% porosity and preferably less than 1% porosity, whereas the top coat will usually be produced with a controlled porosity of between 5 and 20%, (e.g. 10%) to maximize its thermal barrier properties.
  • reinforcing continuous fibers may be incorporated in any of the layers to improve the mechanical properties of the component. This is accomplished by providing a spool within the vacuum plasma spray chamber from which the fibers are fed while deposition of the layers is carried out.
  • the present invention also includes a method of near net-shape forming by VPS of the multilayered combustion system components described above which comprises:
  • the mold may be a destructible mold, which means that after each operation it will be destroyed by removing it, for example, through chemical or electrochemical means. In such a case it is usually made of a soft metal, such as copper, and is used with components of complex geometries from which it cannot be mechanically withdrawn after cooling.
  • the mold may be a re-usable mold, in which case it will be made of steel (eg. stainless steel), graphite or other suitable material which, after cooling is mechanically removed, and which may then be re-used to make further components.
  • the mold may be either solid or hollow.
  • the mold should have a smooth surface, such as to enable VPS forming of components with smooth inside surface, and it should be capable of withstanding and operating at high temperatures.
  • the method of the present invention would comprise the following steps:
  • the mold is usually heated to a surface temperature of about 400°C - 700°C prior to spraying the top coat layer thereon, however, if a debonding layer is first sprayed onto the mold, the mold is normally heated to a surface temperature below 400°C when applying the debonding layer, although one may start applying such layer even when the mold has not been preheated, since the surface of the mold will be rapidly heated by the plasma torch used to apply the debonding layer.
  • the torch heating may be assisted using heat from another source, such as infrared lamps directed towards the mold, or when the mold is hollow, a heating coil may be placed within such hollow mold to provide additional heat when required.
  • thermally insulate regions of the mold which do not require deposition e.g. the two ends of the cylindrical mold used to form combustor liners, may be capped with ceramic prior to the VPS operation.
  • the ceramic top coat layer which may consist of a mixture of ZrO 2 and Ca 2 SiO 4 , is usually deposited to a thickness of between 250 ⁇ m and 1.5 mm depending on thermal barrier requirements.
  • the porosity of the ceramic top coat is also normally controlled so as to maximize its thermal barrier properties.
  • the most commonly employed top coat is ZrO 2 because it has a very low thermal conductivity, however, it cannot be deposited to thicknesses above about 250 ⁇ m because it will then have a tendency to spall. It has been found that admixtures of ZrO 2 with Ca 2 SiO 4 obviate this problem and allow much thicker top coat deposits.
  • Ca 2 SiO 4 has about twice the thermal conductivity of ZrO 2 , an admixture thereof with zirconia allows to increase the thickness of the top coat layer, and the higher the quantity of calcia-silica, the thicker the top coat layer that can be built-up.
  • the ceramic top coat layer has been produced, its surface is normally heated to about 700°C - 800°C prior to applying the metallic bond coat, which is built-up to a thickness of between about 100 ⁇ m and 200 ⁇ m, typically about 150 ⁇ m. Then, after formation of the bond coat, whose surface temperature is maintained at about 700°C - 800°C, the metallic structural layer of e.g. IN-738LC superalloy is vacuum plasma sprayed to a thickness of between 1 and 5 mm.
  • the metallic structural layer of e.g. IN-738LC superalloy is vacuum plasma sprayed to a thickness of between 1 and 5 mm.
  • the final step in the present VPS net-shape forming method is the cooling of the obtained structure and the removal of the mold from the produced multilayered component.
  • the multilayered component such as the combustor liner
  • the mold will detach itself from the mold at the debonding layer during the cool down of the structure. It is at this point that the mold is removed mechanically from the near net-shape component.
  • the mold is removed chemically or electrochemically by selecting a good etchant or electrolyte which will quickly disintegrate the mold material, but without affecting the VPS formed layers.
  • the resulting near net-shape formed multilayered component has a smooth thermal barrier coating as its inside surface and a good, strong structural layer for example of IN-738LC superalloy as its outer structure.
  • the component may also be heat treated to further improve the mechanical properties of the structural layer or may be machined down to a smaller size of outer dimensions. Due to the use of smooth mold surface and of the VPS process, a very high smoothness of the inside surface may be achieved, normally less than 25 ⁇ m R z , which to applicants' knowledge is not achievable by any other process and is unknown in this type of components.
  • this debonding layer should be sufficiently strong to provide enough adhesion between the mold and the top coat to allow for the build-up of the entire multilayered component, whereas the second role is that this debonding layer should be weak enough for allowing detachment or debonding of the mold from the final component upon subsequent cooling of the structure.
  • the debonding layer is normally made of the same material as the top coat (or some similar compatible material that will satisfy the above requirements) and is vacuum plasma sprayed at a relatively low temperature (usually below 400 °C) with spray parameters that form a cooler and faster plasma jet. These spray conditions provide enough adhesion at the mold surface for the required build-up, but not high enough to maintain the bond during cool down.
  • the difference in the coefficient of thermal expansion between the mold (high CTE) and the ceramic top coat (lower CTE) creates a tensile stress greater than the adhesive or cohesive bond strength at the debonding layer region leading to separation of the two.
  • the debonding layer Once the debonding layer has been applied to the mold, the latter is heated to a temperature of between about 400°C and 700°C prior to applying the top coat.
  • This also plays two roles, one being an improved adhesion of the further deposits and the controlling of stress within the coatings at their interfaces, and the other being the expansion of the mold prior to build-up of the various layers, which facilitates removal of the mold when it contracts during the subsequent cool down.
  • step (a) mold 10 is preconditioned by applying a thin debonding layer 12 thereto through vacuum plasma spraying of this debonding layer with the plasma torch 14. This is done at a relatively low temperature of less than 400°C with 2-4 passes of the plasma jet 18 effected by rotation of the mold 10 using rotating means 16. Thereafter, the mold 10 is heated using jet 18 of the same plasma torch 14, to a temperature of between 400°C and 700°C.
  • step (b) the various layers of the multilayered component 20, starting with the inner TBC and ending with the outer structural layer are spray formed by VPS through successive deposits of such layers using plasma torch 14 emitting plasma jet 18 and various powders 19, while rotating the structure by rotating means 16 to successively deposit the multilayered component 20.
  • the temperature and vacuum conditions as well as other spray parameters are adjusted as needed between deposition of the successive layers.
  • step (c) the structure is cooled down and mold 10 is mechanically removed from the multilayered component 20 from which it can be readily separated due to the existence Of debonding layer 12 deposited in step (a).
  • the near net-shape component 20 is obtained in step (d) where it can optionally be heat treated to improve the mechanical properties of the outer structural layer made, for instance, of Inconel or IN-738LC superalloy, and/or it can be machined down to a smaller size.
  • the mold has a complex geometry such as that of the transition duct, the mold can then be made of a soft metal, such as copper, and no deposition of the debonding layer is required in step (a) where the mold is simply heated to the desired temperature of between 400°C - 700°C. In step (c) such mold is removed by disintegration via chemical or electrochemical means as already mentioned previously.
  • Fig. 2 illustrates an arrangement of a combustor liner 22 and a transition duct 24 and shows by a thick arrow the passage of the hot gas therethrough.
  • a turbine between the combustor liner 22 and the transition duct 24, there are normally provided additional combustor liners forming the so called combustor basket.
  • the compressor discharge air is mixed with the fuel combusted near the top of the combustor basket.
  • the basket is designed to contain the flame, to mix-in diluent air, to control temperature emissions and smoke, to channel the hot gases into the turbine, and to provide for air cooling of the metal walls.
  • the combustor liner 22 and the transition duct 24 have been near net-shape formed by VPS in accordance with the present invention and have a multilayered structure shown in cross-section in Fig. 3 for the combustor liner made with a re-usable mold and in Fig. 4 for the transition duct made with a destructible mold.
  • the cross-section shows a thin remainder 26 of the debonding layer left after removal of the mold. It is usually made of a ceramic material, such as ZrO 2 , and is ⁇ 0.01 mm in thickness. It effectively becomes part of the ceramic top coat 28, since it is generally made of the same material as the top coat, except that it is sprayed onto the mold at a lower surface temperature than the top coat, namely with the surface temperature of the mold being about 300°C - 400°C, although the spraying may begin without preheating the mold. Then, top coat 28 is sprayed onto the debonding layer 26 after heating said debonding layer to a temperature between 400°C and 700°C.
  • the top coat 28 may, for example, be made of ZrO 2 -Ca 2 SiO 4 admixture and normally has a thickness > 1mm.
  • a metallic bond coat 30 is sprayed thereon after heating the surface 29 of the top coat 28 to a temperature of between about 700°C and 800°C.
  • This bond coat 30 may, for example, be made of CoNiCrAlY alloy and has a thickness of ⁇ 0.15 mm.
  • this bond coat 30 has been deposited, its surface 31 is preheated to or maintained at a temperature between about 700°C and 800°C and a structural layer 32 is then sprayed thereon.
  • This structural layer 32 may be made, for instance, of superalloy IN-738LC and has a thickness of, for example, 1 - 5 mm.
  • Fig. 4 illustrates a structure similar to that of Fig. 3, but made using a destructible mold, for instance made of copper, which is later removed by destroying it through chemical or electrochemical means.
  • a destructible mold for instance made of copper, which is later removed by destroying it through chemical or electrochemical means.
  • no initial debonding layer is applied, but rather the top coat 28 is directly applied to a mold preheated between 400°C and 700°C .
  • bond coat 30 and structure layer 32 are successively applied as already described with reference to Fig. 3. It should be mentioned that additional desired layers or coatings, including reinforcing fibers, may be incorporated into the structure.
  • This example illustrates the fabrication of a combustor liner according to the present invention.
  • a mold of stainless steel 304 was used for this example.
  • the outer diameter of the mold was machined so as to achieve a near net-shape of the inner diameter of the desired combustor liner, taking into account the mold expansion factor (determined from previous trials). In this case, it was machined so as to achieve a combustor liner of 18 cm internal diameter.
  • the mold surface was grit blasted and ultrasound cleaned prior to its introduction into the VPS chamber. Upon closing the chamber door, the system was pumped down to 6 x 10 -3 mbar.
  • the spray formed part was physically removed from the mold.
  • the part had an overall wall thickness of approximately 6.4 mm, and an inside surface roughness of approximately 19.1 ⁇ m R z .
  • the structural superalloy layer was then machined down to achieve an overall wall thickness of 4.5 mm.
  • cylindrical combustor liners are used in can-type combustors.
  • Several combustor liners are arranged around the engine, with the can axis more or less parallel to the shaft.
  • Primary combustion air and fuel are injected at one end of the can and combust. some of the primary combustion air flows over the outside of the liner and enters through nozzles downstream. Secondary and tertiary air, passes over the outside of the primary combustor liner, thus providing some cooling.
  • Combustor liners undergo abrupt temperature fluctuations resulting in low cycle fatigue (LCF); the combustion process generates high-frequency vibrations which can also induce high cycle fatigue (HCF) failures.
  • the relatively thin walls of the conventional liners make oxidation of the structural alloy a concern.
  • the pressure outside the combustor liner is higher than the inside, which enables the secondary and tertiary air flow through the wall perforations. This difference in pressure, in combination with the thin-nature of the liner wall, may lead to creep problems for the component.
  • the weld in the liner wall and the roughness of its internal surface also represent problems that have already been discussed above.
  • a combustor liner with a thicker, more uniform, and smoother TBC can be fabricated to better resist the low cycle fatigue, high cycle fatigue, oxidation, and creep.
  • Other improvements include: better superalloy material for structural layer; exclusion of welding from the fabrication process; and lower temperature exposure of superalloy.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)

Claims (11)

  1. Endabmessungnahe Komponente von Verbrennungseinrichtungen, die durch Vakuumplasmaspritzen geformt ist, beispielsweise eine Brennkammerauskleidung (22) oder eine Übergangs- bzw. Transitionsführung (24) einer Gasturbine, umfassend:
    a. einen inneren keramischen Decküberzug (28) mit einer gleichförmigen Dicke zwischen 0,25 mm und 1,5 mm sowie einer glatten Innenfläche;
    b. einen zwischengeschalteten metallischen Haftüberzug (30) aus MCrAIY, wo M gleich Ni, Co, Fe oder eine Kombination hiervon mit einer Dicke zwischen 0,1 mm und 0,2 mm, die geringer als die des keramischen Decküberzugs (28) ist, bedeutet; und
    c. eine äußere Superlegierungsstrukturschicht (32) mit einer Dicke zwischen 1 mm und 5 mm, die innerhalb der Komponente variieren kann und in der Lage ist, Temperaturen oberhalb 700°C auszuhalten, wobei diese äußere Strukturschicht (32) keinerlei Nähte oder Schweißungen irgend einer Art darin hat.
  2. Komponente nach Anspruch 1, wobei der keramische Decküberzug (28) gewählt ist aus teilweise stabilisiertem Zirkoniumoxid, Kalziumoxld-Siliziumoxid und einer Kombination hiervon, aufgetragen mit einer Porosität von 5 - 20 %.
  3. Komponente nach Anspruch 1 oder 2, wobei die glatte Innenfläche des keramischen Decküberzugs (28) über eine Rauheit von weniger als 25 µm Rz verfügt.
  4. Komponente nach Anspruch 1, 2 oder 3, wobei die Superlegierungsstruktur (32) eine Superlegierung auf Nickelbasis oder Kobaltbasis mit guten Eigenschaften hinsichtlich Struktur und thermischer Beständigkeit ist.
  5. Verfahren zum Formen einer endabmessungnahen Komponente eines Mehrschichtverbrennungssystems durch Vakuumplasmaspritzen, wobei die Komponente über wenigstens einen inneren keramischen Decküberzug (28), einen zwischengeschalteten metallischen Haftüberzug (30) und eine äußere Superlegierungsstrukturschicht (32) verfügt, umfassend:
    a. Vorsehen einer Form (10) innerhalb einer Vakuumplasmaspritzkammer, wobei die Form über die Gestalt der Innenfläche der gewünschten Komponente verfügt;
    b. Erwärmen dieser Form (10) auf einer Oberflächentemperatur von 400°C - 700°C und Vakuumplasmaspritzen dieser Form mit dem keramischen Decküberzug (28), bis eine gewünschte Dicke hiervon erreicht ist;
    c. dann Erwärmen des so erzeugten keramischen Decküberzugs (28) auf eine Oberflächentemperatur zwischen 700°C und 800°C oder Aufrechterhalten einer solchen Temperatur und Vakuumplasmaspritzen hierauf einer dünnen Schicht des metallischen Haftüberzugs (30);
    d. anschließendes Vakuumplasmaspritzen auf dem so erzeugten Haftüberzug (30), der auf einer Temperatur zwischen 700°C und 800°C gehalten ist, der Superlegierungsstrukturschicht (32), bis eine gewünschte Dicke hiervon erreicht ist; und
    e. Kühlen der so erzeugten Struktur und Entfernen der Form (10) hiervon, derart, dass die endabmessungsnahe Mehrschichtkomponente von innen nach außen in einem einzigen Gesamtvorgang geformt wird.
  6. Verfahren nach Anspruch 5, wobei die Form (10) wieder verwendbar ist und wobei eine dünne Trennschicht (26) aus keramischem Material im Vakuumplasma-Spritzverfahren hierauf vor dem Spritzen der keramischen Deckschicht (28) aufgebracht wird.
  7. Verfahren nach Anspruch 5, die Verwendung einer zerstörbaren Form für Komponenten (24) von komplexer geometrischer Gestalt umfassend, wobei die Form nach dem Kühlen der Struktur durch chemische oder elektrochemische Mittel entfernt wird.
  8. Verfahren nach Anspruch 5, wobei das Erwärmen der Form unter Zuhilfenahme einer äußeren Wärmequelle durchgeführt wird.
  9. Verfahren nach Anspruch 8, wobei die Form (10) hohl ist und die äußere Heizquelle eine in die hohle Form eingeführte Heizspule ist.
  10. Verfahren nach einem der Ansprüche 5 bis 9, wobei Verstärkungsfasern in wenigstens eine Schicht der Komponente (22, 24) zur Verbesserung von deren mechanischen Eigenschaften eingearbeitet werden.
  11. Verfahren nach einem der Ansprüche 5 bis 10, wobei die erzeugte Komponente zur Verbesserung der mechanischen Eigenschaften der Strukturschicht (32) wärmebehandelt wird.
EP98112560A 1997-07-29 1998-07-07 Endabmessungsnahe Mehrschichtkomponenten einer Verbrennungsvorrichtung, gemäss des Vakuum-Plasmaspritzverfahrens und Verfahren zu dessen Herstellung Expired - Lifetime EP0897020B1 (de)

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CA002211961A CA2211961C (en) 1997-07-29 1997-07-29 Near net-shape vps formed multilayered combustion system components and method of forming the same

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US6087023A (en) 2000-07-11
DE69818769T2 (de) 2004-08-05
EP0897020A1 (de) 1999-02-17
DE69818769D1 (de) 2003-11-13
US6296723B1 (en) 2001-10-02

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